Rear Bumper/Snowflap; Windshield/Console/Headlight - Arctic Cat ZR4000 Service Manual

SNO-511
2. Connect the taillight harness connector; then secure
the taillight to the taillight support with the two
screws. Tighten to 48 in.-lb.

Rear Bumper/Snowflap

REMOVING BUMPER
1. Remove and retain only the two machine screws
securing the rear of the skid frame assembly.
2. Place cardboard or a suitable substitute on the floor to
protect the snowmobile from being scratched; then
install Steering Post Stand for the standard steering mod-
els or Handlebar Stand for the adjustable steering models
into the lower holes in the handlebar riser (from the
left-side) and tip the snowmobile onto its left side.
CAUTION
The stand must be used when tipping the snowmobile
onto the right side. Failure to use the stand may dam-
age the oil fill neck.
3. Swing the skid frame assembly away from the chas-
sis; then using a 3/16-in. drill bit, remove all rivets
securing the left-side of the bumper; then repeat for
opposite side.
4. Remove and retain the two machine screws and nuts
securing the front of the existing bumper to the chassis.
5. Remove the two rivets securing the snowflap to the
bumper. Remove the bumper.
INSTALLING BUMPER
1. Align the holes in the bumper with the existing holes
in the tunnel; then using new rivets, secure rear
bumper to the tunnel; then secure the snowflap to the
rear bumper using new rivets.
2. Secure the front of the bumper to the chassis using
the existing machine screws and nuts. Tighten
securely.
3. Install skid frame assembly using two existing
machine screws. Tighten securely.
REMOVING SNOWFLAP
1. Drill out the four rivets securing the snowflap to the
tunnel; then remove the torx-head screw and nut.
2. Remove the snowflap.
INSTALLING SNOWFLAP
1. Secure the snowflap to the tunnel with the torx-head
screw and nut.
2. Add the appropriate rivets to secure the snowflap to
the tunnel.
Windshield/Console/
Headlight
REMOVING
1. Remove and retain all machine screws securing the
hood; then disconnect the console harness and care-
fully remove the hood assembly.
2. Remove the four screws securing the windshield to
the console; then remove the windshield.
3. Remove the four screws securing the windshield
brace to the console. Disconnect the gauge; then
remove the windshield brace assembly.
PC104A
4. Disconnect the electrical accessory wires and igni-
tion switch.
5. Remove the two screws securing the rear of the con-
sole to the hood.
6. Lift the front of the console from the headlight
assembly; then disengage the side console tabs and
remove the console.
PC108
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